There is a technological need for hard thin films with high elastic modulus. Silicon Carbide (SiC) fulfills such requirements with a variety of applications in high temperature and MEMS devices. A detailed study of SiC thin films mechanical properties was performed by means of nanoindentation. The report is on the comparative studies of the mechanical properties of epitaxially grown cubic (3C) single crystalline and polycrystalline SiC thin films on Si substrates. The thickness of both the Single and polycrystalline SiC samples were around 1-2 µm. Under indentation loads below 500 µ-Newton both films exhibit Elastic contact without plastic deformation. Based on the nanoindentation results polycrystalline SiC thin films have an elastic modulus and hardness of 422 plus or minus 16 GPa and 32.69 plus or minus 3.218 GPa respectively, while single crystalline SiC films elastic modulus and hardness of 410 plus or minus 3.18 Gpa and 30 plus or minus 2.8 Gpa respectively. Fracture toughness experiments were also carried out using the nanoindentation technique and values were measured to be 1.48 plus or minus 0.6 GPa for polycrystalline SiC and 1.58 plus or minus 0.5 GPa for single crystal SiC, respectively. These results show that both polycrystalline SiC thin films and single crystal SiC more or less have similar properties. Hence both single crystal and polycrystalline SiC thin films have the capability of becoming strong contenders for MEMS applications, as well as hard and protective coatings for cutting tools and coatings for MEMS devices.

Thin films that are functionally gradient improve the mechanical properties of film-substrate layered materials. Mechanical properties of such materials are found by using indentation tests. In this study, finite element models are developed to simulate the indentation test. The models are based on an axisymmetric half space of a specimen subjected to spherical indentation. The film layer through the thickness is modeled to have either homogeneous material properties or nonhomogeneous material properties that vary linearly. Maximum indenter displacement, and maximum normal and shear stresses at the interface are compared between the homogeneous model and the nonhomogeneous model for pragmatic contact length to film thickness ratios of 0.2 to 0.4, and film to substrate moduli ratios of 1 to 200 to 1. Additionally, a coefficient is derived from regression of the stress data produced by these models and compared to that used to define the pressure field in the axisymmetric Hertzian contact model. The results of this study suggest that a displacement boundary condition to an indenter produces the same results as a pressure distribution boundary condition. The critical normal stresses that occur between modeling a film as a nonhomogeneous and as a homogeneous material vary from 19% for a modulus ratio of 2.5:1 to as high as 66% for a modulus ratio of 200:1 indicating that the modeling techniques produced very different maximum normal stresses. The difference in the maximum shear stress between the nonhomogeneous and the homogeneous models varied from 19% for a 2.5:1 modulus ratio to 57% for the 200:1 modulus ratio but reached values as low as 6% for the 50:1 modulus ratio. The maximum contact depth between the nonhomogeneous and the homogeneous models varied from 14% for the 2.5:1 case to as much as 75% in the 200:1 case. The results from the reapplication of the pressure field derived from the regression coefficients and the R2 values from these regression models indicate the correctness of the regression model used as well as its ability to replicate the normal stresses in the contact area and maximum indenter displacements in a FEA model for both the homogeneous and the nonhomogeneous models for modulus ratios ranging from 2.5:1 to 200:1. The agreement between the regression based coefficients and the force based coefficients suggests the validity for the use of the theoretical axisymmetric Hertzian contact model for defining the pressure field in the contact area and displacements for both the homogeneous case and the nonhomogeneous case for the considered film to substrate moduli ratios and contact length to film thickness ratios.

The thesis is concerned with the contact mechanics behaviour of non-conforming solids. The geometry of the solids considered gives rise to various contact configurations, from concentrated contacts with circular and elliptical configuration to those of finite line nature, as well as those of less concentrated form such as circular flat punches. The radii of curvature of mating bodies in contact or impact give rise to these various nonconforming contact configurations and affect their contact characteristics, from those considered as semi-infinite solids in accord with the classical Hertzian theory to those that deviate from it. Furthermore, layered solids have been considered, some with higher elastic modulus than that of the substrate material (such as hard protective coatings) and some with low elastic moduli, often employed as tribological coatings (such as solid lubricants). Other bonded layered solids behave in viscoelastic manner, with creep relaxation behaviour under load, and are often used to dampen structural vibration upon impact. Analytic models have been developed for all these solids to predict their contact and impact behaviour and obtain pressure distribution, footprint shape and deformation under both elastostatic and transient dynamic conditions. Only few solutions for thin bonded layered elastic solids have been reported for elastostatic analysis. The analytical model developed in this thesis is in accord with those reported in the literature and is extended to the case of impact of balls, and employed for a number of practical applications. The elastostatic impact of a roller against a semi-infinite elastic half-space is also treated by analytic means, which has not been reported in literature. Two and three-dimensional finite element models have been developed and compared with all the derived analytic methods, and good agreement found in all cases. The finite element approach used has been made into a generic tool for all the contact configurations, elastic and viscoelastic. The physics of the contact mechanical problems is fully explained by analytic, numerical and supporting experimentation and agreement found between all these approaches to a high level of conformance. This level of agreement, the development of various analytical impact models for layered solids and finite line configuration, and the development of a multi-layered viscoelastic transducer with agreed numerical predictions account for the main contributions to knowledge. There are a significant number of findings within the thesis, but the major findings relate to the protective nature of hard coatings and high modulus bonded layered solids, and the verified viscoelastic behaviour of low elastic modulus compressible thin bonded layers. Most importantly, the thesis has created a rational framework for contact/impact of solids of low contact contiguity.

Conselho Nacional de Desenvolvimento CientÃfico e TecnolÃgico / As propriedades mecÃnicas de nano e micro sistemas tÃm motivado muitos estudos com o objetivo de entender como a interaÃÃo mecÃnica afeta os materiais em pequenas dimensÃes. A nanoindentaÃÃo foi desenvolvida no inÃcio dos anos 1970 e à amplamente usada para extrair propriedades mecÃnicas de materiais, como por exemplo, o mÃdulo de Young. Tem-se observado que modelos matemÃticos clÃssicos da mecÃnica do contato com base no contato Hertziano (derivado do contato elÃstico semi-infinito) nÃo descrevem adequadamente os campos de tensÃo e deformaÃÃo devido aos efeitos do substrato e tamanho do indentador. Esse trabalho tem por objetivo adaptar o modelo proposto por Hertz para simular o contato entre indentadores com uma superfÃcie de espessura finita. O mÃtodo de elementos finitos (MEF) foi utilizado para modelar as geometrias do contato esfÃrico e cÃnico, permitindo a investigaÃÃo da resposta mecÃnica desses contatos por simulaÃÃes de indentaÃÃo computacional. Os dados obitidos pelo MEF permitiram o ajuste do modelo de Hertz e fatores de correÃÃo foram incluidos para levar a informaÃÃo da espessura da amostra e assim melhorar o entendimento do efeito do substrato em nanoindentaÃÃes. Esses ajustes do modelo de Hertz em conjunto com os dados experimentais de microscopia de forÃa atÃmica sÃo importantes no estudo das propriedades mecÃnicas de materiais biolÃgicos, pois fornece a possibilidade de obter dados quantitativo e qualitativos a respeito do comportamento elÃstico de sistemas em pequena escala.

This diploma thesis deals with the development of experimental apparatus for measuring the real contacts. Phase Shift Interferometry was used for measuring the contacts of steel or brass ball and glass plate. The approach which is desci-bed in this thesis is a unique. It was demonstrated, that the deformation of con-tact body is possible to determine. There is some discusion about final aplicati-on of this optic profilometry for measuring real contacts.

Elaboration of design principles of steel joints. Creation of the finite element model in ANSYS program, the study of static behaviour near the bolt hole, deformation of the screw and the stress components of the welded joint. Comparison with the analytical formulas.

Les phénomènes dynamiques observés lors de la circulation des trains provoquent des nuisances, notamment sonores et vibratoires, qui sont amplifiées par la présence de défauts sur la roue et sur le rail. Pour les analyser, il est nécessaire de prédire avec robustesse le comportement dynamique des composants impliqués dans l’interaction véhicule-voie et donc de simuler les efforts de contact générés pour des interfaces non idéalisées.L’objectif de cette thèse est donc de proposer un modèle semi-analytique global compatible avec l’intégration de multiples défauts géométriques sur les surfaces en contact. Afin de simuler l’interaction véhicule-voie dans le domaine temporel et garantir une applicabilité en phase de dimensionnement, une attention particulière est portée sur le compromis entre la précision des résultats et les temps de calcul associés.Le modèle ainsi proposé est composé d’un demi-bogie, dont le comportement vertical est représenté par un ensemble de masses-ressorts-amortisseurs, circulant sur une voie ballastée. Cette dernière est assimilée à une poutre bi-appuyée, supportée périodiquement à l’emplacement des traverses. Ces deux systèmes sont couplés en contact grâce à une procédure Distributed Point Reacting Spring (DPRS) sous forme discrétisée.Une validation du modèle est, d’une part, proposée en considérant des travaux antérieurs dans le cas de géométries parfaites. D’autre part, de multiples combinaisons de défauts, localisés comme le méplat ou répartis comme l’usure ondulatoire, sont introduites dans la simulation. La variabilité spatiale, particulière au cas de l’écaillage, est modélisée par des champs aléatoires. / The appearance of dynamic phenomena during the running of train on track leads to issues such as noise and vibration pollution, which can be further amplified by the presence of defects on the treads. In order to analyze them, it is necessary to predict with reliability the dynamic behavior of the vehicle-track interaction components, in particular the contact forces produced by non perfect treads.The aim of this PhD thesis is to provide a semi-analytical vehicle-track interaction model able to take into account multiple defects on the surfaces in contact. In order to conduct simulations in the time-domain and ensure applicability in the sizing phase, a special attention is given on the compromise between the accuracy of the results and the simulation times.The proposed model is therefore composed of half a bogie running on a ballasted track. This latter is modeled by a pinned-pinned beam with periodic supports located at the sleepers while the vertical behavior of the bogie is given by masses, springs and dampers. These two models are coupled in contact by a discretized Distributed Point Reacting Spring (DPRS) procedure.A validation of the model, based on previous work, is firstly proposed for perfect treads. Then, multiple combinations of defects, either localised as wheelflat or spread as corrugation, are introduced in the simulation. The spatial variability, specific to shelling, is modeled by random fields.

Mobile Miner 40V is a machine used for rock excavation and developed by Epiroc. This machine is equipped with a large cutter wheel to perform the excavation. After a test run, some surfaces associated with bearings within the cutter wheel were found to be damaged due to scuffing - severe sliding wear. There is a static load applied to the surfaces due to gravity. However, the reason for this damaged issue was believed that there is a large dynamic load applied to the surfaces during the excavation. This dynamic load was not found in a previous FE model used to verify safety issues. Therefore, a new FE model that is more in line with reality, and a failure analysis were required. Additionally, a feasibility study for a cutter wheel with a larger dimension was also needed since a larger cutter wheel is desirable. Firstly, wear mechanisms were reviewed, and some theories were chosen to analyze the damaged issue. Since it was unknown whether the surfaces were well-lubricated or not, both cases were investigated. The Archard wear equation was used to analyze the poor-lubricated situation, while the lubrication number and the Reynolds equation were used to analyze the well-lubricated case. Secondly, contact mechanisms between the surfaces were also investigated. The investigation of the contact mechanisms involved several theories, such as the Hertzian contact theory and the impact load factor. Besides these theoretical analyses, a numerical analysis was performed. Lastly, a new FE model was established in Ansys. Both the cutter wheel which was subjected to scuffing(existing cutter wheel), and the cutter wheel with a larger dimension(larger cutter wheel) were analyzed by the use of the new FE model. The maximum and minimum wear rates obtained by the Archard wear equation are approximately 1.9・10-2mm3/m and 4.8・10-3mm3/m, which are considered as a completely unacceptable level in engineering applications. The maximum and minimum critical loads obtained by the Reynold equation are approximately 1.8kN and 24.8kN, which both are larger than the static load applied to the surfaces. The maximum and minimum critical mean contact pressures obtained by the lubrication number are approximately 65MPa and 240MPa, which both are larger than the mean contact pressure generated by the static load. No evidence shows that there is a large dynamic load applied to the surfaces during the excavation. The largest possible contact pressure on the bearings in the existing cutter wheel is very close to the limit of severely damaged. The largest possible contact pressure on the bearings in the larger cutter wheel is believed to exceed the limit of severely damaged. The previous assumption that the surfaces were damaged due to a large dynamic load was wrong. The obtained results support that the surfaces were only subjected to a static load and were damaged due to inadequate lubrication. The existing cutter wheel is operated safely with the current load cases. However, the forward thrust force is suggested to decrease when the cutting angle is large. There is a high risk if the larger cutter wheel is operated with the current load cases.

No description available.

This bachelor’s degree project aimed to improve the wheel profile of a rail mounted trolley and determine the cause of wheel failure. The proceedings of this project where modelled after an approach for solving wear problems with an emphasis on designing for sustainability. A case study and root cause analysis (RCA) was performed and the flanged wheels were deemed insufficient for the given heavy-haul system. Possible areas of wheel profile improvement were identified and further researched with multiple literature reviews. Throughout the projects duration several limitations were introduced that reduced the concept testing to exclusively theoretical prediction models. Archard’s model was implemented to predict wear and operating time for the proposed material and wheel tread profile concepts. The wheel flange dimensions were chosen based on recommendations from wheel and rail interference handbooks among other sources. The final wheel and rail profile suggestion improved operating time by approximately 300% and wear resistance by 50% compared to its predecessor. This result was achieved by applying the same theoretical prediction model to both current and suggested profiles. The findings of this project are meant to aid SCA among others in similar cases and additionally highlight the value of product improvement from a technological, sociological, and environmental perspective.